Dangerous ground Ned. Any advice given/taken that has not been endorsed by Caterham will/could invalidate the guarantee at the subsequent 'Board of Enquiry'. On the other hand, if they find something missing/wrong and it is not in the manual then they will be obliged to rectify it at their expense. For instance; now that I know the engine mount bolts need a spring washer then it will be on my 'snagging list' for the post build check and they can put one in at their cost and rectify any alignment snags that result due to everything else being bolted up around the engine; or indemnify me for any long term problems the lack of a spring washer might invite.   

I take your point... And you're right, the lack of detail in the manual has strengthened claims and won arguments in the past, I know. 

But my idea is just to collect the pearls of wisdom from here, and possibly add some different photos. Would this be any more problematic than listing them on Blatchat?

I'm going to do it anyway, for my own benefit, and I'm very happy to share with others in the 160 family!

I take your point... And you're right, the lack of detail in the manual has strengthened claims and won arguments in the past, I know. 

But my idea is just to collect the pearls of wisdom from here, and possibly add some different photos. Would this be any more problematic than listing them on Blatchat?

I'm going to do it anyway, for my own benefit, and I'm very happy to share with others in the 160 family!

There is some bloke doing the upgrade to the manual. I'm not sure if everyone is aware but since last June I've been in dialogue with Caterham about the 80+ discrepancies I found in the manual and that was before I started my build. It got to the point where I contacted their chief commercial officer who was very apologetic but here we are 10 months later and no update.  I have been in email exchange with the head tech guy and I spent 90 mins on the phone in Nov last year explaining all the errors I found, but I must admit to some frustrations especially after today's fiasco with the engine mounts.

im up for helping anyone with their build but I think Caterham should own the official manual and everything we do as a community should stay offline, only my opinion 

regards

martin

See previous blog - if anyone is in doubt whether they have this bit or not, this is what the Clutch Cable Retaining Clamp (which neither Simon or I got) looks like with a v small allen key in it.  /sites/default/files/images/users/11787/Clutch%20Cable%20Clamp.jpg. Fuse Panel Cover fixed with black velcro and seems to be OK. Also used the hole in the cover to mount my 12v scoket, which also seems to work. 

Hi Simon - I think it has, the pedal has 'settled' 10mm below the brake and, as the clutch plate spring is now influencing in both directions, it 'feels right'. Amazing though that fitting it has been left out of the latest manual draft and such a vital bit was not in our kits.

Hi Both, I have one of these but not sure how to fit it, can either of you enlighten me?

Thanks

Martin

Ah Ah, I've think I've just twigged, does it go on the opposite side of the clutch lever so it has pressure from the clutch spring in both directions?

Martin

Hi Peter, where did you get your 12v socket from?

Regards

Martin

Hi Al, just a quick update on the tax, after a extensive email exchange with Crawley it seems the 160 tax is £145, not the £30 quoted by the dealer.  It seems that small manufacturers can't use the CO rating and it is based on 2 bands above and below a 1400cc value so the 160 is in the lower band at £145, seems a swizz to me.

Simon sorry to hear about the non starting engine, in the good old days you could pull the spark plug out and check, pull the fuel feed of the carb, etc but with all this modern plumbing this is no longer possible.  I too have the 2 unconnected pipes near the throttle body and I'm sure you've checked all the other connections. Does the interia cut out switch behind the brake master cylinder have any role to play?  I've also read that the 160 long term test in Car magazine had problems with the immobiliser and does this need to be programmed or linked to the car before it will start

Martin

I bought my 12v socket straight off the net. Got a push and twist one so the plug-in won't shake loose. Used standard crimped male and female spade connectors and heat shrunk the cables together to form a 'rats tail' off the loom connection. Tie wrapped it to the loom and it looks the part.

A current owner told me that if it doesn't start it is usually the Inertia Switch that needs to be reset. Is it possible that the inertia switch (on bulkhead behind the master cylinder) re-circs fuel back to the tank e.g. you would hear the pump going but no fuel would get to the engine. 

Simon - did you use an auto, tyre-air driven, brake bleeder. If so someone has 'blogged' elsewhere that he had to revert to the traditional 'pedal' method to get the final bit of air out of the system after using one. 

Me - I had a 'revitting' day on the interior panels and my hands and wrists ache! 

Hi I bled my brakes today just used the old fashioned way by a tube over the nipples into a jar of fluid, took a few goes but got there in the end but it is a 2 man task. Also got my wings on and the interior trim in. Just the riveting to go and then the rad and intercooler, then onto the weather gear.  Simon hope your engine is starting soon

martin

Hi Simon, well they feel firm and there is no more air bubbles.  I couldn't get all the air out at first so actually started at the front RHS, once the fluid starting moving out of the master cylinder then I stopped and went back to normal sequence.  So start at the longest run, the back, then both LHS front nipples and then finally the 2 RHS frontones.  I didn't use an EZY bleed, I went with the straight pipe over the nipple into a clear jar of fluid and then pushing on the pedal and holding down the pedal when you nip the nipple up.  It is a 2 man job and getting the fluid moving at the start was my main issue.  Sorry to hear about the engine, I'm at a bit of a loss to know what next?

Regards

Martin

Hi Simon bit of a long shot but have you checked the earth leads, I guess the engine wouldn't turn if the earth was poor but it may be the loom earth  that is worth checking

regards

martin